U.S. patent number 10,058,102 [Application Number 14/176,276] was granted by the patent office on 2018-08-28 for dough forming pressing plate with spacers.
This patent grant is currently assigned to Lawrence Equipment Inc.. The grantee listed for this patent is Lawrence Equipment Inc.. Invention is credited to Eric C. Lawrence.
United States Patent |
10,058,102 |
Lawrence |
August 28, 2018 |
Dough forming pressing plate with spacers
Abstract
In some embodiments, a dough pressing system includes means for
coupling a cover to a pressing platen, wherein the cover can reduce
the wear caused to the pressing platen by the heat and pressure
used to process one or more products. The cover optionally can be
configured to be removably attached to the pressing platen with
vacuum pressure. In some implementations, one or more spacers are
placed between the cover and the pressing platen. The thickness of
the spacers can adjust the thickness and diameter of products
processed by the pressing platen. For example, to increase
uniformity among products pressed together in a press cycle, the
spacers can have different thicknesses that correspond with the
location of the spacer in the pattern of dough balls.
Inventors: |
Lawrence; Eric C. (So. El
Monte, CA) |
Applicant: |
Name |
City |
State |
Country |
Type |
Lawrence Equipment Inc. |
N/A |
N/A |
N/A |
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Assignee: |
Lawrence Equipment Inc. (South
El Monte, CA)
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Family
ID: |
44936598 |
Appl.
No.: |
14/176,276 |
Filed: |
February 10, 2014 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20140153813 A1 |
Jun 5, 2014 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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12940012 |
Nov 4, 2010 |
8689685 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A21C
11/006 (20130101); B30B 15/062 (20130101); G06T
7/97 (20170101) |
Current International
Class: |
G01B
7/00 (20060101); G01B 15/00 (20060101); G06T
7/00 (20170101); B30B 15/06 (20060101); A21C
11/00 (20060101) |
References Cited
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EP |
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EP |
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Primary Examiner: Yi; Roy Y
Attorney, Agent or Firm: Fish & Richardson P.C.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of and claims
priority to U.S. application Ser. No. 12/940,012, filed on Nov. 4,
2010, the contents of which are incorporated herein by reference.
Claims
What is claimed is:
1. A method comprising; receiving, by a pressed comestible
monitoring station, one or more images of a plurality of pressed
comestible products from one or more imaging devices included in
the pressed comestible monitoring station; determining, by the
pressed comestible monitoring station, a pressing pattern i) that
identifies a quantity of comestible products concurrently processed
at a comestible pressing apparatus and ii) that identifies, for
each of the quantity of comestible products, a position within the
comestible pressing apparatus at which the respective comestible
product is processed to create a respective pressed comestible
product; determining, by the pressed comestible monitoring station
and for one or more of the plurality of pressed comestible products
using the one or more images, a) a position identified by the
pressing pattern at which the respective pressed comestible product
was created in the comestible pressing apparatus and b) one or more
diameters for the respective pressed comestible product;
determining, by the pressed comestible monitoring station and for
each position identified by the pressing pattern, one or more
average diameters for the position using the one or more diameters
for the pressed comestible products from the plurality of pressed
comestible products that were created in the comestible pressing
apparatus at the corresponding position; determining, by the
pressed comestible monitoring station and for each position
identified by the pressing pattern, a variance between the one or
more average diameters for the position and a desired diameter for
each of the plurality of pressed comestible products; generating,
by the pressed comestible monitoring station using the variance for
each position identified by the pressing pattern, instructions for
presentation of a user interface that (i) includes a representation
of the pressing pattern with position representations for each of
the positions identified by the pressing pattern, and at which the
comestible pressing apparatus processes comestible products, and
(ii) associates, for each position identified by the pressing
pattern, the respective variance with the respective position
representation in the representation of the pressing pattern; and
providing, by the pressed comestible monitoring station to a
monitor, the instructions for presentation of the user interface to
cause the monitor to present the user interface.
2. The method of claim 1, wherein determining, for each position
identified by the pressing pattern, the one or more average
diameters from the one or more diameters comprises applying a
weighting factor to each of the one or more diameters.
3. The method of claim 2, wherein applying the weighting factor to
each of the one or more diameters comprises: determining, for each
of the one or more diameters, a variance between the respective
diameter and the desired diameter; applying a larger weight to a
first diameter from the one or more diameters that has a larger
variance from the desired diameter; and applying a smaller weight
that is less than the larger weight, to a second diameter from the
one or more diameters, the second diameter having a smaller
variance that is less than the larger variance, from the desired
diameter.
4. The method of claim 1, comprising: receiving, by a product
rejection device from the pressed comestible monitoring station,
data that identifies one or more rejected products from the pressed
comestible products that have an actual diameter that varies from
the desired diameter by more than a threshold variance; and in
response to receiving the data, separating, by the product
rejection device, the one or more rejected products from the other
pressed comestible products that have an actual diameter that does
not vary from the desired diameter by more than the threshold
variance.
5. The method of claim 1, wherein receiving the one or more images
of the plurality of pressed comestible products from the one or
more imaging devices comprises: receiving multiple images from the
one or more imaging devices, the multiple images comprising the one
or more images and one or more second images; determining, by the
pressed comestible monitoring station, that the one or more images
depict the plurality of pressed comestible products using the hue,
saturation, and value of the content of the one or more images; and
determining, by the pressed comestible monitoring station, that the
one or more second images do not depict the plurality of pressed
comestible products using the hue, saturation, and value of the
content of the one or more second images, wherein: determining, for
the one or more of the plurality of pressed comestible products
using the one or more images, the one or more diameters for the
respective pressed comestible product is responsive to (a)
determining that the one or more images depict the plurality of
pressed comestible products and (b) determining that the one or
more second images do not depict the plurality of pressed
comestible products.
6. The method of claim 1, comprising: identifying, by the pressed
comestible monitoring station, a spacer thickness recommendation
for a position in the pressing pattern using one or more of the
determined variances between the average diameters and the desired
diameter; and automatically adjusting, using the spacer thickness
recommendation, a spacer corresponding with the position in the
pressing pattern of the comestible pressing apparatus that forms
the plurality of pressed comestible products by changing, using the
spacer thickness recommendation, an applied pressure at the
position in the pressing pattern.
7. The method of claim 1, comprising: identifying, by the pressed
comestible monitoring station, a spacer thickness recommendation
for a position in the pressing pattern using one or more of the
determined variances between the average diameters and the desired
diameter; and adding a spacer to or removing a spacer from the
position in the pressing pattern of the comestible pressing
apparatus that is between a pressing plate that applies a first
pressure to a plurality of non-pressed comestible products to
create the plurality of pressed comestible products and a skin
removably attached to the pressing plate, the comestible pressing
apparatus including the pressing plate and the skin.
8. The method of claim 1, comprising: identifying, by the pressed
comestible monitoring station, a spacer thickness recommendation
for a position in the pressing pattern using one or more of the
determined variances between the average diameters and the desired
diameter; removing, by the comestible pressing apparatus, a skin
from the comestible pressing apparatus; and placing a second skin
in the comestible pressing apparatus, the second skin including one
or more second spacers corresponding with the spacer thickness
recommendation for the position in the pressing pattern.
9. The method of claim 1, comprising: identifying, by the pressed
comestible monitoring station, a spacer thickness recommendation
for a position in the pressing pattern using one or more of the
determined variances between the average diameters and the desired
diameter, wherein: generating the instructions for presentation of
the user interface comprises generating the instructions for the
user interface that identifies, for the position representation
that corresponds to the position in the pressing pattern, the
spacer thickness recommendation; and providing, to the monitor, the
instructions to cause the monitor to present the user interface
comprises providing, to the monitor, the instructions to cause the
monitor to present the spacer thickness recommendation.
10. The method of claim 9, wherein the spacer thickness
recommendation for the position in the pressing pattern indicates a
recommendation whether to change a current spacer thickness at the
position in the pressing pattern.
11. The method of claim 9, wherein the spacer thickness
recommendation for the position in the pressing pattern specifies a
thickness that should be added to or removed from a spacer at the
position in the pressing pattern in the comestible pressing
apparatus.
12. The method of claim 9, wherein identifying the spacer thickness
recommendation comprises: retrieving production history data from a
production history database; and identifying, using the production
history data, the spacer thickness recommendation.
13. The method of claim 12, comprising: determining a current grid
of variance values for the pressing pattern using the variance for
each position identified by the pressing pattern; and comparing the
current grid of variance values for the pressing pattern with a
plurality of historical variance grids for the pressing pattern,
wherein the plurality of historical variance grids are included in
the production history database and each correspond with a spacer
recommendation, wherein identifying the spacer thickness
recommendation comprises determining the spacer thickness
recommendation using a historical variance grid, from the plurality
of historical variance grids for the pressing pattern, that is most
similar to the current grid of variance values for the pressing
pattern.
14. The method of claim 12, comprising: determining one or more
second diameters for a second plurality of pressed comestible
products; and updating the production history database with data
representing the spacer thickness recommendation and the second
diameters for the second plurality of pressed comestible
products.
15. The method of claim 12, comprising: determining one or more
second diameters for a second plurality of pressed comestible
products; and updating the production history database with a
variance between the second diameters and the desired diameter
using machine learning.
16. The method of claim 1, wherein generating the instructions for
presentation of the user interface comprises generating the
instructions for the user interface that includes: the
representation of the pressing pattern in a first location of the
user interface; and a pressed comestible preview section in a
second location of the user interface that (a) presents a video
sequence of images received from the one or more imaging devices
that depict one or more of the plurality of pressed comestible
products and (b) indicates, for each of the depicted pressed
comestible products, a quality of the respective pressed comestible
product.
17. The method of claim 1, wherein generating the instructions for
presentation of the user interface comprises generating the
instructions for the user interface that identifies, for each
position identified by the pressing pattern, a diameter range (a)
for the pressed comestible products from the plurality of pressed
comestible products that were created in the comestible pressing
apparatus at the corresponding position and (b) that is identified
using the one or more diameters for the pressed comestible products
that were created in the comestible pressing apparatus at the
corresponding position.
18. The method of claim 1, comprising: identifying, by the pressed
comestible monitoring station, a spacer thickness recommendation
for a position in the pressing pattern using one or more of the
determined variances between the average diameters and the desired
diameter; and providing, by the pressed comestible monitoring
station, the spacer thickness recommendation for the position in
the pressing pattern to a spacer adjustment module for changing,
using the spacer thickness recommendation, an applied pressure at
the position in the pressing pattern.
19. The method of claim 18, wherein providing, by the pressed
comestible monitoring station, the spacer thickness recommendation
for the position in the pressing pattern to the spacer adjustment
module comprises causing the spacer adjustment module to adjusting,
using the spacer thickness recommendation, a skin or a spacer
located between the skin and a pressing plate in the comestible
pressing apparatus.
20. The method of claim 18, comprising: retrieving recipe
parameters from a product parameter database, wherein the recipe
parameters indicate the desired diameter for the pressed comestible
products and a variance threshold value; determining that the
variance between the average diameter for a second position in the
pressing pattern and the desired diameter exceeds the variance
threshold value; and presenting the determined average diameter for
the second position and the recipe parameters on the monitor,
wherein: identifying, by the pressed comestible monitoring station,
the spacer thickness recommendation for the position in the
pressing pattern is responsive to determining that the variance
between the average diameter for the second position in the
pressing pattern and the desired diameter exceeds the variance
threshold value; and the spacer thickness recommendation is based
on the variance between the average diameter for the second
position in the pressing pattern and the desired diameter, and the
variance threshold value.
21. The method of claim 20, wherein the position in the pressing
pattern and the second position in the pressing pattern are the
same position in the pressing pattern.
22. A system for monitoring comestible products, the system
comprising: a monitoring station that includes a) one or more
imaging devices each of which are configured to capture one or more
images of each pressed comestible product from a plurality of
pressed comestible products, and b) one or more storage devices
storing instructions that are operable, when executed by the
monitoring station, to cause the monitoring station to perform
operations comprising: determining a pressing pattern i) that
identifies a quantity of comestible products concurrently processed
at a comestible pressing apparatus and ii) that identifies, for
each of the quantity of comestible products, a position within the
comestible pressing apparatus at which the respective comestible
product is processed to create a respective pressed comestible
product; receiving one or more images of a plurality of pressed
comestible products from the one or more imaging devices;
determining one or more diameters for one or more of the pressed
comestible products from the plurality of pressed comestible
products that correspond with a first position in the pressing
pattern and that were created in the comestible pressing apparatus
at the first position; determining an average diameter for the
first position in the pressing pattern from the one or more
diameters; determining a variance for the first position that is a
difference between the average diameter and a desired diameter;
generating, using the variance for the first position in the
pressing pattern, instructions for presentation of a user interface
that (i) includes a representation of the pressing pattern with a
location representation for each position in the pressing pattern
including a first location representation for the first position,
and (ii) indicates, for the first location representation in the
representation of the pressing pattern, the variance for the first
position; and providing the instructions to a monitor to cause
presentation of the user interface on the monitor; and the monitor
configured to receive the instructions and, in response, present
the user interface.
23. The system of claim 22, comprising: the comestible pressing
apparatus comprising: a support surface that supports a surface of
each of the plurality of pressed comestible products; a pressing
plate that applies a first pressure to a plurality of non-pressed
comestible products to create the plurality of pressed comestible
products; and a first skin removably attached to the pressing
plate; and a spacer adjustment module that changes a distance
between the first skin and the pressing plate or removes the first
skin from the pressing plate and facilitates attachment of a second
skin to the pressing plate.
24. The system of claim 22, comprising: a product rejection station
configured to remove one or more of the pressed comestible products
that have an actual diameter that varies from the desired diameter
by more than a threshold variance from (a) the system and (b) the
other pressed comestible products that have an actual diameter that
does not vary from the desired diameter by more than the threshold
variance.
25. The system of claim 22, comprising: a production history
database including a plurality of historical variance grids for the
pressing pattern and spacer recommendations for each of the
historical variance grids, the operations comprising: determining a
current grid of variance values for the pressing pattern; comparing
the current grid of variance values for the pressing pattern with a
plurality of historical variance grids for the pressing pattern;
and determining a spacer thickness recommendation using a
historical variance grid, from the plurality of historical variance
grids for the pressing pattern, that is most similar to the current
grid of variance values for the pressing pattern.
26. The system of claim 22, comprising: a production history
database including a plurality of historical variance grids for the
pressing pattern, the operations comprising: identifying a spacer
thickness recommendation for a position in the pressing pattern
using one or more of the determined variances between the average
diameters and the desired diameter; causing, using the spacer
thickness recommendation, a change to an applied pressure at the
position in the pressing pattern; determining one or more second
diameters for a second plurality of pressed comestible products
after causing the change to the applied pressure at the position in
the pressing pattern; and updating the production history database
with data representing the spacer thickness recommendation and the
second diameters for the second plurality of pressed comestible
products.
Description
BACKGROUND
Flatbread is made from flour, water, and salt and formed into
flattened dough before baking. Some flatbreads include additional
ingredients such as curry powder, black pepper, olive oil, or
sesame oil. The thickness of the flattened dough can range from one
thirty-second of an inch to over an inch thick.
Flatbreads are made by hand or with automated equipment. For
example, a factory can be used to produce one or more types of
flatbread to reduce the costs of making the bread. Some automated
methods of forming flatbread include die cutting, sheeting, and
pressing of flatbread dough.
Factories can include different types of tools for the different
stages in the production process, such as a mixer. Some production
lines have a tool to form flatbread dough into a ball and another
tool to flatten the dough for baking. The flattened dough has a
circular shape and a specific thickness so the flatbread will have
a desired thickness after baking.
For example, a pressing apparatus presses a ball of dough until the
pressed dough ball has a certain diameter. After the pressure is
released from the pressed dough ball, the diameter of the pressed
dough ball sometimes decreases. Changes to different process
parameters, such as a heating temperature during pressing and the
ingredients in the dough, sometimes have an effect on the diameter
of the dough after pressing is completed. For example, a higher
pressing temperature can help a pressed dough ball retain is
shape.
SUMMARY
In some embodiments, a dough pressing system includes means for
coupling a cover to a pressing platen, wherein the cover can reduce
the wear caused to the pressing platen by the heat and pressure
used to process one or more products. The cover optionally can be
configured to be removably attached to the pressing platen with
vacuum pressure.
In some implementations, one or more spacers are placed between the
cover and the pressing platen. The thickness of the spacers can
adjust the thickness and diameter of products processed by the
pressing platen. For example, to increase uniformity among products
pressed together in a press cycle, the spacers can have different
thicknesses that correspond with the location of the spacer in the
pattern of dough balls.
The thermal conductivity of the spacers and the cover is optionally
selected based on the processing temperature of the products. For
example, the composition of the spacers can be selected so that the
spacers efficiently transfer heat from the pressing platen to the
cover.
In certain implementations, spacer thicknesses are determined based
on the actual diameter of products currently being processed by the
pressing platen. For example, a spacer adjustment module can
compare the current product diameters and the variance from a
desired product diameter with history data associated product
diameters and variance with spacer adjustments. The spacer
adjustment module can select process history information related to
the product diameters and variance values and identify a spacer
thickness recommendation based on the process history
information.
The details of one or more implementations are set forth in the
accompanying drawing and description below. Other features,
objects, and advantages will be apparent from the description and
drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is an example of a dough pressing apparatus.
FIGS. 2A-B are an example of a pressing station.
FIG. 3A-C illustrate an example of a skin.
FIGS. 4A-B illustrate an example of a skin mounted to a pressing
plate.
FIGS. 5A-C illustrate an example of vacuum grooves in an upper
platen.
FIG. 6 is an example of the dough pressing apparatus of FIG. 1 with
the skin removed from the upper pressing platen.
FIG. 7 illustrates an example of a latitudinal aligner.
FIGS. 8A-B illustrate an example of a longitudinal aligner.
FIGS. 9A-B illustrate examples of spacers used to adjust dough
thickness.
FIG. 10 is an example of a system for identifying a thickness
adjustment for a spacer in a dough pressing apparatus.
FIG. 11 illustrates an example user interface for entering recipe
parameters.
FIG. 12 illustrates an example user interface presenting a grid of
average variance values.
FIG. 13 illustrates an example user interface presenting recipe
history information.
FIG. 14 illustrates another example user interface presenting
recipe history information.
FIGS. 15A-B show an example of a product monitoring station.
FIG. 16 is a block diagram of a computing system optionally used in
connection with computer-implemented methods described in this
document.
Like reference symbols in various drawing indicate like
elements.
DETAILED DESCRIPTION OF ILLUSTRATIVE IMPLEMENTATIONS
During flattening of balls of dough, an upper pressing platen
applies pressure against the top surfaces of the balls of dough
while a lower pressing platen applies pressure on the balls of
dough from below. The upper pressing platen includes a pressing
plate and a skin covering the bottom surface of the pressing plate.
The skin (or cover) contacts the upper surface of the balls of
dough while heating the dough to form and maintain a flat circular
shape.
One or more spacers are placed between the skin and the pressing
plate to increase size uniformity (e.g., diameter and thickness)
between all of the balls of dough being flattened at the same time
(e.g., a pattern of dough balls or a press cycle) and between
patterns of dough balls being processed during the same recipe run.
The thermal conductivity of the spacers is selected so that heat
from the pressing plate travels through the spacers and heats the
skin so the balls of dough have the correct processing
temperature.
If the diameter of a pressed ball of dough varies from a desired
diameter by more than a threshold variance, the thickness of a
spacer corresponding to the location the ball of dough was pressed
at is adjusted so that the diameter of later balls of dough
processed at the same location with respect to the pressing plate
have a diameter within the threshold variance from the desired
diameter.
The spacers have varying thicknesses corresponding to a spacing
adjustment needed at a specific point between the pressing plate
and the skin so that all the balls of dough in a press cycle have a
size within the threshold variance. For example, one of the spacers
can have a thickness of about 0.001 inches while another spacer
contacting a different part of the skin has a thickness of about
0.385 inches.
A center vertical axis of the spacers aligns with a center vertical
axis of a corresponding ball of dough before the ball of dough is
flattened and during the pressing process. For example, the balls
of dough are placed on a conveyor belt in specific positions so
that the centers of the balls of dough will line up with the
centers of the spacers when the conveyor moves the balls of dough
below the upper platen. Sometimes, if the axes of a ball of dough
and a corresponding spacer do not align, one side of the flattened
dough extends past an edge of the spacer and the pressed ball of
dough will have an irregular shape and/or the pressed ball of dough
might be out of a diameter specification.
In certain implementations, for some of the locations in a pattern
of dough balls, a spacer is not placed between the pressing plate
and the skin. For example, if the size of a ball of dough is within
the threshold size variance, a spacer is not required between the
skin and pressing plate for that location in the pattern of dough
balls.
A seal around the outer edge of the pressing plate allows the skin
to be releasably attached to the pressing plate by vacuum suction.
The vacuum suction permits the use of different thicknesses of
spacers between the pressing plate and the skin while the skin
remains in thermal contact with the pressing plate. For example,
the skin stays in contact with either the spacers or the pressing
plate and remains at an approximately uniform temperature during
processing of the balls of dough.
When the balls of dough are pressed by the skin, the temperature of
the skin, the spacers, and the upper pressing plate can decrease
because of the heat conducted to the balls of dough. In some
implementations, a thermocouple measures the temperature of the
upper pressing plate and the temperature of heating coils in the
upper pressing plate is adjusted based on the measured temperature
of the upper pressing plate to keep the upper pressing plate at an
approximately uniform temperature. In other implementations, a
software module predicts temperature changes in the upper pressing
plate, and the temperature of the heating coils is adjusted based
on the predicted temperature.
Use of vacuum suction allows the skin to be easily removed from the
pressing plate for maintenance and/or spacer adjustment. For
example, if a non-stick coating on a bottom surface of the skin
becomes worn, the vacuum pressure between the skin and pressing
plate is removed so that a different skin can be placed on the
bottom of the pressing plate.
In some implementations, thermal grease is applied to the spacers.
The thermal grease helps hold the spacers in place with respect to
the pressing plate and the skin and increases the transfer of heat
between the pressing plate, and the skin.
FIG. 1 is an example of a dough pressing apparatus 100. The dough
pressing apparatus 100 includes a conveyor 102 that receives one or
more balls of dough 104. The balls of dough 104 are placed on the
conveyor 102 by a loading station or another conveyor (not shown).
The temperature of the conveyor 102 is the same as the ambient
environment around the dough pressing apparatus 100.
The conveyor 102 moves a pattern of dough balls into a pressing
station 106, which presses the balls of dough 104 and forms a
plurality of pressed dough balls 108. The actual diameters of the
pressed dough balls 108 are measured for accuracy to determine how
close the diameters are to a desired diameter.
In some implementations, the pressure used at the pressing station
106 is adjusted based on the actual diameters of the pressed dough
balls 108 if a number of the pressed dough balls 108 have a
diameter that is smaller or larger than the desired diameter. For
example, if there are nine balls of dough in a press cycle, and six
of the pressed dough balls 108 have an actual diameter that is
smaller than the desired diameter, the pressure used by the
pressing station can be increased so that the diameters of the
pressed dough balls 108 increases.
The pressing station 106 includes an upper pressing platen 110 that
applies pressure to the balls of dough 104 from above, as shown in
more detail in FIGS. 2A-B. The upper pressing platen 110 includes
an upper insulator 112, an upper pressing plate 114, and an upper
portion 116. The upper insulator 112 and the upper pressing plate
114 are mounted to the upper portion 116 with non-conductive
bolts.
The upper insulator 112 provides thermal insulation so that heat
from the upper pressing plate 114 does not pass into the upper
portion 116 of the upper pressing platen 110. The upper insulator
112 is made from thermalate, such as Thermalate.RTM. H330
manufactured by Haysite. The upper insulator 112 has a maximum
service temperature between about 500 and about 1000.degree. F.,
preferably between about 500 to about 850.degree. F., more
preferably between about 550 to about 800.degree. F. The upper
insulator 112 has a compressive strength between about 17,000 to
about 49,000 PSI, preferably between about 26,200 to about 49,000
PSI, more preferably between about 26,200 to about 44,000 PSI. In
some implementations, the upper insulator 112 is composed of
glastherm, such as Glastherm.RTM. HT or Cogetherm.RTM. manufactured
by Glastic Corporation.
The upper insulator 112 and the upper pressing plate 114 are square
with a length L.sub.P and a width W.sub.P between about 12 to about
72 inches, preferably between about 15 to about 60 inches. In
certain implementations, the upper insulator 112 has a rectangular
shape. In some implementations, the upper insulator 112 and the
upper pressing plate are square with a width W.sub.P and length
L.sub.P between about 37 to about 42 inches. The upper insulator
112 has a thickness between about 1/2 to about 2 inches, preferably
between about 3/4 to about 13/4 inches, more preferably about 3/4
inches.
The upper pressing plate 114 includes one or more heating channels
(not shown). The heating channels include one or more heating
elements that increase the temperature of the upper pressing plate
114 during processing. In some implementations, a heating fluid,
such as a liquid or a gas, flows through the heating channels in
order to heat the upper pressing plate. For example, Argon gas
passes through the heating channels and heats the upper pressing
plate 114 to a temperature between about 150 to about 750.degree.
F., preferably between about 250 to about 550.degree. F., more
preferably between about 300 to about 400.degree. F.
The thickness of the upper pressing plate 114 is selected based on
the pressure applied to the balls of dough 104 and the temperature
required to heat the balls of dough during processing. For example,
the upper pressing plate 114 has a thickness between about 1 to
about 5 inches, preferably between about 11/2 to about 3 inches.
For example, the finished thickness of the upper pressing plate 114
can be about 2.974 inches.
In some implementations, the thickness of the upper pressing plate
114 is selected based on the composition of the upper pressing
plate 114. For example, when the upper pressing plate 114 is made
from graphene, the upper pressing plate 114 has a lesser thickness
than if the upper pressing plate 114 was made from gold.
The upper pressing plate 114 is made from a material with a high
thermal conductivity. The upper pressing plate 114 has a thermal
conductivity between about 5 to about 5500 W/(m*K), preferably
between about 15 to about 2500 W/(m*K), more preferably between
about 30 to about 500 W/(m*K).
In some implementations, the composition of the upper pressing
plate 114 is selected based on the resistance of the material to
wear or scratches. For example, stainless steel is used to increase
hardness (e.g., durability) and corrosion resistance of the upper
pressing plate 114. The increased hardness of stainless steel
decreases scratches and dents made to the upper pressing plate
114.
In some implementations, the upper pressing plate 114 is
manufactured from aluminum or an aluminum alloy in order to have
high wear resistance, a light mass, and a reduced heating time
(e.g., based on a thermal conductivity of about 120 to about 237
W/(m*K)). The upper pressing plate 114 can be made from ceramic
material in order to withstand high processing temperatures without
deforming (e.g., up to about 3,000.degree. F.) and have a high wear
resistance. Brass can be used for the upper pressing plate 114
based on the low friction of brass materials and good thermal
conductivity (e.g., about 109 W/(m*K)).
In certain implementations, the upper pressing plate 114 is
manufactured from diamonds and has an increased durability and a
high thermal conductivity (e.g., between about 900 to about 2,320
W/(m*K)). Similarly, the upper pressing plate 114 can be composed
of graphene to have a high durability and thermal conductivity
(e.g., between about 4,840 to about 5,300 W/(m*K)). Copper or a
copper alloy can be used for the upper pressing plate 114 for good
thermal conductivity (e.g., about 401 W/(m*K)). Alternatively,
silver, with a high thermal conductivity (e.g., about 429 W/(m*K)),
can be used for the composition of the upper pressing plate 114. In
some implementations, the upper pressing plate 114 is made from
gold based on the thermal conductivity of gold (e.g., about 318
W/(m*K)). In some implementations, lead, with a thermal
conductivity of about 35.3 W/(m*K) can be included in the
composition of the upper pressing plate 114.
The upper pressing platen 110 includes a skin 118 that protects the
bottom surface of the upper pressing plate 114 from wear caused by
heat and/or pressure during processing of the balls of dough 104.
For example, a pressure between about 3 to about 70 PSI is applied
to the upper pressing platen 110 to press a bottom surface of the
skin 118 against the balls of dough 104, preferably between about 5
to about 65 PSI. In some implementations, a pressure between about
9 to about 50 PSI is applied to the upper pressing platen 110.
The pressing station 106 uses different pressures based on the
desired diameter of the pressed dough balls 108. For example, a
higher pressure (e.g., 48 PSI) is used to create pressed dough
balls with a larger diameter (e.g., 12 inches) and a lower pressure
(e.g., 13 PSI) is used to create pressed dough balls with a smaller
diameter (e.g., 5 inches).
The diameter of the pressed dough balls 108 is inversely
proportional to the thickness of the pressed dough balls 108. For
example, increasing the diameter of a specific pressed dough ball
decreases the thickness of the specific pressed dough ball. In one
example, a ball of dough with a specific volume has a diameter of
10 inches and a thickness of 1/4 inches, and a ball of dough with
the same volume and an 8 inch diameter has a thickness of 25/64
inches.
The pressing station 106 includes a lower pressing platen 120. The
lower pressing platen 120 applies pressure to the balls of dough
104 from below during processing. For example, the lower pressing
platen 120 supports the balls of dough 104 on the conveyor 102
while the upper pressing platen 110 presses down on the top surface
of the balls of dough 104.
The lower pressing platen 120 includes a lower pressing plate 222
and a lower insulator 224. The lower pressing plate 222 has a
similar configuration (e.g., size and composition) to that of the
upper pressing plate 114. For example, the lower pressing plate 222
is heated and has a thermal conductivity of between about 5 to
about 5500 W/(m*K), preferably between about 15 to about 2500
W/(m*K), more preferably between about 30 to about 500 W/(m*K).
In some implementations, the lower pressing plate 222 has a lower
temperature than the upper pressing plate 114 in order to reduce
the likelihood that a ball of dough will stick to the skin 118
after being pressed. For example, the pressed dough balls are more
likely to stick to a cooler surface, so the temperature of the
lower pressing plate 222 is less than the temperature of the upper
pressing plate 114 and the skin 118 so that the pressed dough balls
108 will rest on the conveyor 102 after processing instead of
sticking to the skin 118 and lifting off of the conveyor 102.
For example, the lower pressing plate 222 has a temperature between
about 150 to about 750.degree. F., preferably between about 250 to
about 550.degree. F., more preferably between about 300 to about
400.degree. F. In one example, when the upper pressing plate 114
has a temperature of around 350.degree. F., the skin 118 has a
temperature of around 340.degree. F., and the lower pressing plate
222 has a temperature of around 325.degree. F.
The lower pressing plate 222 optionally has a different size or
composition than the upper pressing plate 114. For example, the
lower pressing plate 222 is manufactured from stainless steel,
which has a higher resistance to wear, and the upper pressing plate
114 is manufactured from aluminum, which has a lower mass and is
easier to lift. In another example, the lower pressing plate 222 is
3 inches thick and the upper pressing plate 114 has a finished
thickness of 2.974 inches thick.
The lower insulator 224 prevents the lower pressing plate 222 from
heating a lower portion 226 of the lower pressing platen 120. The
lower insulator 224 has is composed of thermalate, such as
Thermalate.RTM. H330 manufactured by Haysite. The lower insulator
has a thickness between about 1/2 to about 2 inches, preferably
between about 3/4 to about 13/4 inches. In some implementations,
the lower insulator 224 is made from glastherm, such as
Glastherm.RTM. HT or Cogetherm.RTM. manufactured by Glastic
Corporation.
FIGS. 3A-C illustrate an example of a skin 300. For example, the
skin 300 is the same as the skin 118 used in the upper pressing
platen 110. The skin 300 includes a substantially flat center
portion 302. An upper surface 304 of the center portion 302 abuts a
bottom surface of the upper pressing plate 114 when the skin 300 is
attached to the upper pressing plate 114 and a lower surface 306 of
the center portion 302 applies pressure against the balls of dough
104 during processing.
The skin 300 includes two lip portions 308a-b that extend from the
latitudinal ends of the skin 300. Each of the lip portions 308a-b
extends upward from the center portion 302. The lip portions 308a-b
extend next to the latitudinal sides of the upper pressing plate
114 when the skin 300 is attached to the upper pressing plate 114,
as described in more detail below.
The width W.sub.S of the skin 300 is the same as the width W.sub.P
of the upper pressing plate 114. For example, if the width W.sub.P
of the upper pressing plate 114 is 42 inches, the width W.sub.S of
the skin 300 is 42 inches. The length L.sub.5 of the skin 300 is
about the same as the length L.sub.P of the upper pressing plate
114. For example, if the length L.sub.P of the upper pressing plate
114 is 42 inches, the length L.sub.S of the skin 300 is between
about 42 to about 43 inches, preferably between about 421/4 to
about 421/2 inches, more preferably about 421/4 inches. The length
L.sub.S of the skin 300 is selected so that the lip portions 308a-b
extend upward past the latitudinal sides of the upper pressing
plate 114 when the skin 300 is attached to the upper pressing plate
114.
In other implementations, the skin 300 is smaller than the upper
pressing plate 114. For example, the size of the skin 300 is
selected based on the pattern of dough balls being processed by a
dough pressing apparatus. The size is large enough to prevent
contact between the pressed dough balls and the upper pressing
plate 114. The smaller size of the skin 300 in this embodiment
reduces the amount of vacuum pressure needed to hold the skin 300
adjacent to the upper pressing plate 114.
In some implementations, the skin 300 has only one lip portion
(e.g., the lip portion 308a). For example, the lip portion 308a is
used to align the skin 300 with the upper pressing plate 114 and as
part of a safety system, described in more detail below.
In certain implementations, the skin 300 does not include either of
the lip portions 308a-b. For example, having a symmetrical shape
can increase heat uniformity across the skin 300.
The skin 300 has a thickness between about 0.03125 to about 2
inches, preferably between about 0.0625 to about 11/2 inches, more
preferably between about 0.080 to about 1 inch. For example, the
thickness of the skin 300 is selected to reduce the chance of
dents, bends, and/or tears occurring in the skin 300.
The skin 300 has a processing temperature of between about 150 to
about 750.degree. F., preferably between about 250 to about
550.degree. F., more preferably between about 300 to about
400.degree. F. Heat is conducted to the skin 300 from the upper
pressing plate 114 and used to during processing of the balls of
dough 104. For example, the contact between the upper surface 304
and the upper pressing plate 114 conducts heat from the upper
pressing plate 114 and into the skin 300.
One or more spacers 310a-f, shown in FIG. 3B, are placed on the
skin 300 between the upper surface 304 and a bottom surface of the
upper pressing plate 114. Each of the spacers 310a-f includes one
or more thermally conductive shims. For example, the spacer 310e
includes two shims, a first with a thickness of 0.025 inches and a
second with a thickness of 0.2 inches, and the spacer 310d includes
one shim with a thickness of 0.03 inches. Each of the shims has a
thickness between about 0.001 to about 0.5 inches, preferably
between about 0.001 to about 0.25 inches, more preferably between
about 0.001 to about 0.1 inches.
In some implementations, the spacers 310a-f introduce slight gaps
between the skin 300 and the upper pressing plate 114. For example,
there can be a small gap between the upper surface 304 and the
upper pressing plate 114 around the circumference of each of the
spacers 310a-f. In certain implementations, the size of the gap is
small such that the gap does not introduce cool spots on the skin
300 that affect processing of the balls of dough 104.
In other implementations, the location of the gap is outside of an
area that touches the balls of dough 104 during processing. For
example, each of the spacers 310a-f has a larger diameter than the
desired diameter of the pressed dough balls 108 and any cool spots
on the skin 300 caused by the gap do not negatively affect
processing.
Each of the shims has a circular shape that corresponds with the
shape of the balls of dough 104. In some implementations, the shims
are square or rectangular with a size greater than a desired
diameter of the pressed dough balls 108. Square shims are used, for
example, based on the ease of manufacturing square shims from sheet
material (e.g., it is easier to cut square shims from sheet
material than circular shims).
The size of the shims is selected based on the desired diameter of
the pressed dough balls 108. The shims have a size that is between
about 10 to about 150% of the desired diameter, preferably between
about 30 to about 150%, more preferably between about 50 to about
150%. For example, when the desired diameter of the pressed dough
balls 108 is 10 inches, each of the shims has a diameter of 12
inches (e.g., 120% the size of the desired diameter).
The diameter of the shims is larger than the desired diameter of
the pressed dough balls 108 because the diameter of the pressed
dough balls 108 decreases with decreasing platen pressure. For
example, a shim with a 12 inch diameter applies pressure on a ball
of dough through the skin 300, forming a pressed dough ball with an
11 inch diameter. When the skin 300 is retracted, the pressed dough
ball tends to return to its original shape (e.g., the shape before
processing) and the diameter of the pressed dough ball decreases to
about 10 inches.
In some implementations, changes in the duration of the pressing
cycle affect the actual diameter of a pressed dough ball. For
example, when pressure is applied to a pressed dough ball for a
longer period of time, the diameter of the dough ball changes less
than when pressure is applied for a shorter period of time.
In one example, the shims have a larger diameter than the desired
diameter so that the pressed dough balls 108 are heated evenly
during processing.
In another example, the diameter of each of the shims is less than
the desired diameter of the pressed dough balls 108. For example,
when the desired thickness of the pressed dough balls 108 is thin
(e.g., between about 1.5 to about 3 mm), the pressure and heat of
the pressing station 106 sometimes causes cracks to form near the
edges of the pressed dough balls 108.
In this example, the heating that helps the pressed dough balls 108
maintain their shape and reduces the moisture in the pressed dough
balls 108, can cause cracks to form. Using shims that are smaller
than the desired diameter of the pressed dough balls 108 creates a
thicker edge around the circumference of the pressed dough balls
108 because a reduced amount of pressure is applied to the dough
that extends beyond the edges of the shims.
The thicker edge around the circumference has a reduced possibility
of cracking because of the additional thickness of the dough. Less
heat is transferred to the thicker edge because of reduced contact
between the shims and the thicker edge, which causes less moisture
to be removed from the thicker edge and reduces the possibility of
cracks forming in the thicker edge. For example, a gap around the
circumference of the shims can cause the surface of the skin 300 to
be slightly cooler around the circumference of the shims so that
less moisture is removed from the portion of the pressed dough ball
that corresponds with the gap around the circumference of the
shims.
In order for the thicker edge of the dough to be uniform, the balls
of dough 104 need to align with the spacers 310a-f. For example, a
central vertical axis 312 of the spacer 310e needs to be aligned as
closely as possible with a central vertical axis of the ball of
dough that will be pressed by the bottom surface of the skin 300
below the spacer 310e.
For example, when the balls of dough 104 are placed on the conveyor
102, as shown in FIG. 1, each of the balls of dough 104 in a press
cycle are spaced evenly apart and the conveyor moves the pattern of
dough balls in a forward direction F to place the pattern of dough
balls in the pressing station 106. When the balls of dough 104 are
in the pressing station 106, center vertical axes 402a-d of the
balls of dough 104, shown in FIG. 4A, align with a central vertical
axis of a corresponding spacer 310a-d.
When the upper pressing platen 110 presses down on the balls of
dough 104 in the press cycle, the centers of the spacers 310a-d
apply pressure to the centers of the balls of dough and the pressed
dough balls 108 are formed, as shown in FIG. 4B.
When the spacers 310a-f have a smaller diameter than the desired
diameter of the pressed dough balls, each of the pressed dough
balls has an edge that is thicker than the center of the pressed
dough ball and the width of the thicker edge is within a threshold
variance based on the alignment of the center vertical axes of the
balls of dough and the spacers 310a-f. For example, the width of
the thicker edge is almost uniform around the circumference of the
pressed dough balls 108.
In some implementations, some of the spacers 310a-f have different
thickness, as shown in FIG. 3C. When some of the pressed dough
balls 108 have different diameters, the thickness of the spacers
310a-f can be adjusted to reduce the variance between the diameters
of the pressed dough balls 108.
For example, when the desired diameter of the pressed dough balls
is 10 inches and a pressed dough ball corresponding with the spacer
310b has an actual diameter of 9.7 inches and a pressed dough ball
corresponding with the spacer 310d has an actual diameter of 10.4
inches, the thickness of the spacers 310b and 310d can be adjusted
so that future pressed dough balls have a diameter closer to 10
inches. The thickness of the spacer 310b, for example, is increased
in order to increase the diameter of corresponding pressed dough
balls and the thickness of the spacer 310d is decreased in order to
decrease the diameter of the dough balls pressed by the spacer
310d.
In certain implementations, when the diameter of the spacers 310a-f
are larger than the desired diameter of the pressed dough balls
108, a spacer is not placed at every potential spacer position on
the skin 300. For example, if the average thickness of pressed
dough balls corresponding with the spacer 310b is about 10.1 inches
when the spacer is 0.001 inches thick, the spacer 310b can be
removed from between the skin 300 and the upper pressing plate 114
so that the average thickness of the dough balls corresponding to
the former location of the spacer 310b is closer to the desired
diameter of 10 inches.
In other implementations, when the diameter of the spacers 310a-f
are smaller than the desired diameter of the pressed dough balls
108, a spacer is required in every potential spacer location on the
skin. For example, each of the pressed dough balls 108 has an edge
that is thicker than the center of the pressed dough ball. In order
to create the thicker edge, at least one shim is needed for each
spacer location so that more pressure is applied to the center of
the dough balls making the center of the pressed dough balls
thinner than the outer edge.
When the spacers 310a-f are shims, thermal grease is applied
between the shims and both the skin 300 and the upper pressing
plate 114 to increase the thermal conductivity between the upper
pressing plate 114, the shims, and the skin 300. The thermal grease
has a thermal conductivity of between about 10 to about 250
W/(m*K). Alternatively, the thermal conductivity is between about
50 to about 300 W/(m*K). In some implementations, the thermal
conductivity of the thermal grease is selected to be between about
30 and about 500 W/(m*K) based on the properties of the skin 300,
the shims, and/or the upper pressing plate 114.
The thermal conductivity of the skin 300 and the spacers 310a-f is
between about 5 to about 5500 W/(m*K), preferably between about 25
to about 3000 W/(m*K), more preferably between about 30 to about
500 W/(m*K). For example, the skin 300 and the spacers 310a-f are
made from aluminum or an aluminum alloy with a thermal conductivity
between about 120 to about 237 W/(m*K). In some implementations,
the skin 300 and the spacers 310a-f have different properties, such
as different thermal conductivities.
When the skin 300 is made from diamonds, the skin 300 has a high
hardness (e.g., reduced wear during use) and high thermal
conductivity (e.g., about 900 to about 2,320 W/(m*K)). The high
hardness of diamond compositions needs to be considered when
forming the skin 300 from diamonds. Alternatively, the skin 300
and/or the spacers 310a-f can be composed of graphene to have a
high durability and thermal conductivity (e.g., about 4,840 to
about 5,300 W/(m*K)). When the skin 300 is made from gold, the
pressure used during processing needs to be adjusted based on the
softness of gold. In some implementations, the spacers 310a-f are
made from silver because of the high thermal conductivity of silver
(e.g., about 429 W/(m*K)). When additional pressure can be applied
to the skin 300 to support the skin 300 and the spacers 310a-f
adjacent to the upper pressing plate 114, the skin 300 and/or the
spacers 310a-f can be made from stainless steel for the thermal
conductivity (e.g., between about 12.11 to about 45.0 W/(m*K)) and
durability of stainless steel. In certain implementations, the
spacers 310a-f can be manufactured from brass for the low friction
and good thermal conductivity of brass (e.g., about 109 W/(m*K)).
The skin 300 can be composed of the same material as the spacers
310a-f or of a different material.
The surface finish of the upper surface 304 of the skin 300, the
upper and lower surfaces of the spacers 310a-f, and the bottom
surface of the upper pressing plate 114 is selected to increase
thermal conductivity. For example, the skin 300 and the spacers
310a-f have a surface finish between about 50 to about 500 Ra
.mu.m, preferably between about 75 to about 400 Ra .mu.m, more
preferably between about 100 to about 250 Ra .mu.m.
The surface finish of the lower surface 306 of the skin 300 is
chosen based on the desired heat transfer between the skin 300 and
the balls of dough 104 and the desired (e.g., low) coefficient of
static friction between the skin 300 and the balls of dough 104
(e.g., so that the pressed dough balls 108 do not stick to the skin
300).
In some implementations, the lower surface 306, the lip portions
308a-b, and/or an outer perimeter 314 of the upper surface 304 are
coated with a non-stick material (e.g., a release agent). Non-stick
materials applied to the lower surface 306 or the outer perimeter
314 have a thermal conductivity between about 10 to about 500
W/(m*K), preferably between about 15 to about 450 W/(m*K), more
preferably between about 30 to about 300 W/(m*K), to transfer heat
to the balls of dough 104 during processing. The non-stick material
has a maximum use temperature between about 350 to about
1000.degree. F., preferably between about 400 to about 800.degree.
F., more preferably between about 450 to about 750.degree. F. In
other implementations, the non-stick material has a maximum
temperature between about 350 to about 650.degree. F., preferably
between about 400 to about 600.degree. F., more preferably between
about 450 to about 550.degree. F.
For example, the lower surface 306 is coated with Teflon (e.g.,
Teflon 532-13054) so that the balls of dough 104 do not stick to
the lower surface 306 during processing. In certain
implementations, grease or oil is applied to the lower surface 306
periodically during processing of the balls of dough 104 to reduce
static friction between the skin 300 and the balls of dough 104.
Sometimes, when the balls of dough include a threshold percentage
of oil, the lower surface 306 of the skin 300 does not need a
non-stick coating.
As shown in FIGS. 4A-B, two lip portions 404a-b extend upward from
the skin 118 adjacent to the latitudinal sides of the upper
pressing plate 114 when the skin 118 is attached to the upper
pressing plate 114. The two lip portions 404a-b are used to align
the skin 118 with the upper pressing plate 114 when the skin 118 is
being attached to the upper pressing plate 114.
In certain implementations, one of the lip portions (e.g., the lip
potion 404a) includes an identifier that is used to align the skin
118 with the upper pressing plate 114. For example, the lip portion
308a, shown in FIG. 3A, includes two apertures 316a-b that
distinguish the lip portion 308a from the lip portion 308b. When
the skin 300 is attached to the upper pressing plate 114, the
apertures 316a-b are used to determine which end of the skin 300 to
align with the latitudinal end of the upper pressing plate 114 that
the balls of dough 104 initially pass under when moving in the
forward direction F.
In some implementations, the temperatures of the upper pressing
plate 114, the skin 118, and the spacers 310a-d decrease when the
upper platen 110 is pressed the balls of dough 104. For example,
the skin 118 transfers heat to the pressed dough balls 108 and the
temperatures of the upper pressing plate 114, the spacers 310a-d,
and the skin 118 decrease. A thermocouple (not shown) measures the
temperature of the upper pressing plate 114 and increases the
temperature of the heating coils in the upper pressing plate 114 to
keep the upper pressing plate 114, the spacers 310a-d, and the skin
118 at an approximately uniform temperature during processing. In
other implementations, a software module predicts temperature
changes in the upper pressing plate 114, and the temperature of the
heating coils is adjusted based on the predicted temperature.
FIGS. 5A-C illustrate an example of vacuum grooves in an upper
platen 500. The upper platen 500 includes an upper pressing plate
502 with a plurality of grooves 504 in a bottom surface 514 of the
upper pressing plate 502. When the bottom surface 514 of the upper
pressing plate 502 contacts a skin 506, shown in FIG. 5C, a vacuum
pump (not shown) connected to the grooves 504 creates vacuum
pressure between the upper pressing plate 502 and the skin 506 and
the vacuum pressure holds the skin 506 against the bottom surface
514 of the upper pressing plate 502.
A seal 508, located around a peripheral edge of the upper pressing
plate 502 as shown in FIGS. 5A-B, facilitates the creation of the
vacuum pressure that holds the skin 506 in place against the bottom
surface 514. When the upper pressing plate 502 initially contacts
the skin 506 an inflatable tube 510, located adjacent to the seal
508, is pneumatically filled with air, causing the seal 508 to move
downward and contact the skin 506. Once the seal 508 contacts the
skin 506 a vacuum seal can be made between the upper pressing plate
502 and the skin 506 using the seal 508.
The upper pressing plate 502 includes a flange 512 around the
bottom circumference of the upper pressing plate 502, which holds
the seal 508 and the inflatable tube 510 in place. The flange 512
is attached to the upper pressing plate 502 with a plurality of
bolts. For example, the flange 512 is made of multiple pieces, and
each of the pieces is connected to the upper pressing plate 502
with two or more bolts.
In some implementations, the skin 506 includes a coating that helps
separate the skin 506 from the seal 508 when the vacuum pressure
between the skin 508 and the upper pressing plate 502 is removed.
For example, an outer perimeter (e.g., the outer perimeter 314) on
the upper surface of the skin 506 is coated with a non-stick
material (e.g., Teflon) so that a vacuum seal is more easily
created between the skin 506 and the seal 508. The non-stick
material has a maximum use temperature between about 350 to about
1000.degree. F., preferably between about 400 to about 800.degree.
F., more preferably between about 450 to about 750.degree. F. In
other implementations, the non-stick material has a maximum
temperature between about 350 to about 650.degree. F., preferably
between about 400 to about 600.degree. F., more preferably between
about 450 to about 550.degree. F.
A vacuum seal between the skin 506 and the upper pressing plate 502
is created to hold the skin 506 in place against the entire bottom
surface 514 and to prevent the skin 506 from warping during
processing of balls of dough. If the skin 506 is allowed to warp,
cool spots can be formed on the skin 506 that affect the uniformity
of balls of dough processed at a pressing station.
The vacuum pressure between the upper pressing plate 502 and the
skin 506 is between about 2 to about 15 PSI, preferably between
about 4 to about 15 PSI, more preferably between about 4 to about
14.7 PSI. In some implementations, the pressure used to create
vacuum suction varies based on the weight of the skin 506 and
spacers placed between the skin 506 and the upper pressing plate
502.
The seal 508 and the inflatable tube 510 are made from silicone. In
some implementations, the seal 508 and/or the inflatable tube 510
are manufactured from an elastomer that can withstand maximum
processing temperatures between about 500 to about 650.degree. F.
without deforming. The hardness of the seal 508 and/or the
inflatable tube 510 is between about 15 to about 100 Durometer,
preferably between about 25 to about 80 Durometer, for A or D type
testing according to ASTM D2240 testing for softer or harder
plastics.
The tensile strength of the seal 508 and/or the inflatable tube 510
is between about 600 to about 1500 PSI, preferably between about
700 to about 1300 PSI. The elongation of the seal 508 is between
about 400 and about 650%, preferably between about 500 and 600%.
The elongation of the inflatable tube 510 is between about 200 to
about 400%, preferably between about 250 and about 350%.
The inner diameter of the inflatable tube 510 is between about 1/8
to about 1 inch. The inner diameter is selected so that the
inflatable tube 510 presses downward on the seal 508 when the
inflatable tube 510 is filled with air and the seal 508 can help
create a vacuum seal between the upper pressing plate 502 and the
skin 506. The outer diameter of the inflatable tube 510 is between
about 5/32 to about 9/8 inches. The outer diameter of the
inflatable tube 510 is selected based on the inner diameter of the
inflatable tube 510 and the desired flexibility of the inflatable
tube. The outer diameter is selected so that the inflatable tube
510, when deflated, does not press downward on the seal 508 and the
vacuum seal between the upper pressing plate 502 and the skin 506
can be removed when processing of the balls of dough is completed
(e.g., to allow maintenance of the skin 506).
In some implementations, when shims are placed between the skin 506
and the upper pressing plate 502, the shims are perforated to
enhance suction between the upper pressing plate 502 and the skin
506. For example, less pressure is required to hold the skin 506
against the upper pressing plate 502 when the shims are perforated.
The perforations in the shims are selected so that the pressed
dough balls are smooth and do not have indentations caused by the
perforations in the shims. In certain implementations, when a
textured surface on the pressed dough balls is desired, the
perforations in the shims are selected based on the desired
texture.
In certain implementations, the upper pressing plate 502 is
attached to the skin 506 with a plurality of screws or bolts. The
upper pressing plate 502 includes a plurality of threaded screw
holes that align with corresponding apertures in the skin 506 that
allow the screws to pass through the skin 506 and attach to the
threaded screw holes. The screws are inserted into the threaded
screw holes through the corresponding apertures and fixed in
place.
Alternatively, the upper pressing plate 502 includes apertures that
allow bolts to pass through the upper pressing plate 502 and attach
to nuts. The nuts are secured to the end of the bolts that passes
through the upper pressing plate 502 and hold the bolts and the
skin 506 in place during processing.
The locations of the apertures are selected based on the pressing
pattern of a recipe currently being used. For example, the
apertures are disposed adjacent to the perimeter of the bottom
surface 514 of the upper pressing plate 502. The location of the
apertures is selected so that the apertures, and the screws or
bolts placed in the apertures, do not align with a ball of dough
during processing of the ball of dough. For example, the apertures
are selected to provide the maximum support for the skin 506 while
not aligning with a spacer placed between the skin 506 and the
upper pressing plate 502. In some implementations, the apertures
are selected so that the apertures do not align with heating
elements (not shown) disposed within the upper pressing plate. The
apertures are selected to that gaps do not form between the bottom
surface 514 and the skin 506 and allow the skin 506 to cool.
In some implementations, the skin 506 is detachably coupled to the
upper pressing plate 502 using one or more electromagnets placed in
the upper pressing plate 502. Each electromagnet includes an
electrically conductive wire wrapped into a coil and when an
electrical current passes through the electrically conductive wire,
the coil generates a magnetic field that attracts paramagnetic and
ferromagnetic materials.
For example, the material for the skin 506 can be paramagnetic
stainless steel that will attach to the upper pressing plate 502
when the electromagnets are turned on. In another example, the
composition of the skin 506 includes iron. Steel and iron are
structurally robust materials that have reduced wear.
When electromagnets are used to couple the skin 506 with the upper
pressing plate 502, a composition of a lower pressing plate (not
shown) is selected so that the lower pressing plate is not
magnetic. For example, the lower pressing plate is made from
aluminum.
In certain implementations, one or more clamps couple the skin 506
to the upper pressing plate 502. For example, two clamps attach
each edge of the skin 506 to the upper pressing plate 502. The
clamps use a compressive force to attach the edges of the skin 506
with the upper pressing plate 502 and hold the skin 506 in place
during processing.
In one example, clamps are used in combination with electromagnetic
coupling to ensure that there are no gaps between the upper
pressing plate 502 and the skin 506. The introduction of gaps can
cause cold spots on the skin 506, which reduce uniformity between
pressed dough balls.
FIG. 6 is an example of the dough pressing apparatus 100 of FIG. 1
with the skin 118 removed from the upper pressing platen 110. For
example, the skin 118 is removed from the upper pressing plate 114
for maintenance of the skin 118.
In some implementations, the skin 118 is removed from the upper
pressing plate 114 when adjustments are required for the spacers
between the skin 118 and the upper pressing plate 114. When the
height of one or more of the spacers needs to be adjusted, all
products (e.g., the balls of dough 104 and the pressed dough balls
108) are removed from the conveyor 102. The upper pressing platen
110 is lowered until the bottom surface of the skin 118 touches the
top of the conveyor 102.
The skin 118 is released from the upper pressing platen 110, for
example, by removing the vacuum pressure holding the skin 118 to
the upper pressing plate 114. The upper pressing platen 110 is
raised so that a back lip portion 628 of the skin 118 can move
beneath the upper pressing platen 110.
The location of the conveyor 102 is indexed before the skin 118 is
moved so that the conveyor 102 can later be positioned back in its
current position and the skin 118 realigned with the upper pressing
plate 114. After indexing, the conveyor 102 is moved in a forward
direction until the skin 118 is no longer beneath the upper
pressing platen 110.
Depending on the maintenance required, the skin 118 can be removed
from the conveyor 102. For example, if a new recipe requires
pressing a 6.times.6 pattern of dough balls and the skin 118 is
configured for pressing a 5.times.6 pattern of dough balls, another
skin configured for pressing a 6.times.6 pattern of dough balls can
be placed on the conveyor. Alternatively, the thickness of spacers
placed on the skin 118 can be adjusted.
Multiple skins can be stored in the same facility housing the dough
pressing apparatus 100 to allow easy exchange of skins that are
configured for different recipes. The different recipes can have
different press cycle layout, such as a square 2.times.2 to a
square 8.times.8 layout or a rectangular 5.times.6 or 4.times.3
layout. Different skins can be configured for different desired
diameters of pressed dough. In some implementations, different
skins are configured for dough with the same thickness. Use of a
first skin will press a ball of dough uniformly on the top surface
and while use of a second skin will press the center of a ball of
dough, leaving the outer edge of the ball of dough thicker than the
center.
In certain implementations, the skin 118 is removed from the upper
pressing platen 110 so that a release agent (e.g., PAM or Teflon)
can be reapplied to the skin 118. When the skin 118 is removed from
the upper pressing platen 110, care should be taken to prevent the
skin 118 from bending, which can reduce the performance of the skin
118 during pressing of balls of dough in the pressing station
106.
The skin 118 is removed from the conveyor 102 and a new skin is
placed on the conveyor 102 manually. In this example, the back lip
portion 628 includes an identifier so that a technician can
differentiate the back lip portion 628 from a front lip
portion.
Proper alignment of the skin 118 with respect to the upper pressing
plate 114 ensures that when spacers of different thicknesses are
placed on the skin 118, the spacers align properly with the upper
pressing plate 114 and pressed dough balls formed by the dough
pressing apparatus 100 have a diameter within a threshold variance
from the desired diameter.
For example, when the dough pressing apparatus 100 forms two
different sizes of pressed dough balls and a change in the recipe
is required, a skin configured for the first diameter is easily
exchanged with a skin already configured for the second diameter
corresponding to the other recipe and the amount of down time
required for the exchange is less than if a single skin or pressing
plate needed to be reconfigured for the other recipe.
After the new skin is placed on the conveyor 102, the conveyor 102
is moved in a backward direction to the indexed position for
alignment of the skin with the upper pressing plate 114. The
pressing station 106 uses the back lip portion 628 to line up the
latitudinal ends of the skin 118 with the upper pressing plate 114.
For example, the back lip portion 628 contacts two latitudinal
aligners 834, shown in FIGS. 8A-B, when aligning with the back edge
of the upper pressing plate 114.
Two longitudinal aligners 732a-b, shown in FIG. 7, on either side
of the skin 118 align the longitudinal edges of the skin 118 with
the longitudinal edges of the upper pressing plate 114 so that a
vacuum seal between the skin 118 and the upper pressing plate 114
can be created. When the skin 118 is properly aligned with the
upper pressing plate 114, an inflatable tube (e.g., the inflatable
tube 510) is filled with air and a seal is formed between the upper
pressing plate 114 and the skin 118 (e.g., by the seal 508).
In some implementations, an automated system removes and replaces
the skin 118 in the pressing station 106. For example, when the
dough pressing apparatus 100 receives input from a user indicating
a recipe change, the dough pressing apparatus 100 determines if the
skin 118 currently attached to the upper pressing plate 114 can be
used for the new recipe. If the skin 118 cannot be used for the new
recipe, the skin 118 is placed on the conveyor 102, moved to an
unloading position, and a mechanical arm (not shown) grips to the
back lip portion 628 and the front lip portion 630 of the skin 118
to remove the skin 118 from the conveyor 102.
The mechanical arm places the skin 118 on a tray and selects a new
skin that is configured for the new recipe. The mechanical arm
positions the new skin on the conveyor 102 and the new skin is
attached, using vacuum pressure, to the upper pressing plate
114.
In order to prevent the skin 118 from accidently falling on the
conveyor 102, one or more safeties 836 connect to holes in the back
lip portion 628. For example, referring to FIG. 3A, the back lip
portion (e.g., the lip portion 308a) includes two apertures 316a-b
that align with the safeties 836. When the skin 118 is attached to
the upper pressing plate 114, the safeties 836 extend into the
apertures 316a-b so that if the vacuum suction should fail, the
back lip portion 628 will be held in place and the skin 118 will
not fall and move along the conveyor 102.
In some implementations, a skin rests on a top surface of the lower
pressing plate 222 (FIGS. 2A-B) to protect the top surface of the
lower pressing plate 222 from wear in a similar manner to the skin
118 protecting a bottom surface of the upper pressing plate 114. In
one example, the skin is connected to the lower pressing plate 222
with fasteners. A user places the skin on the top surface of the
lower pressing plate 222, centers the skin on the lower pressing
plate 222 by aligning the edges of the skin with the edge of the
lower pressing plate 222 and secures the fasteners in place.
In certain implementations, the lower skin is detachably coupled to
the lower pressing plate 222 with vacuum. Using vacuum pressure to
attach the lower skin to the lower pressing plate 222 allows the
lower skin to be easily removed from the lower pressing plate 222
for maintenance. Alternatively, the lower skin is attached to the
lower pressing plate 222 with screws or bolts. In these
implementations, the lower skin includes apertures that allow the
bolts to pass through the lower skin and connect to the lower
pressing plate 222. In some implementations, the lower skin is held
adjacent to an upper surface of the lower pressing plate 222 with
one or more electromagnets.
The skin is removed from and attached to the lower pressing plate
222 during a maintenance cycle. For example, the conveyor 102 is
removed from the dough pressing apparatus 100 to allow the skin to
be replaced. Alternatively, the lower pressing platen 120 slides
out from under the conveyor 102 to allow a user access to the lower
skin. In some implementations, the skin 118 is removed from the
upper pressing plate 114 during the same maintenance cycle.
In certain implementations, spacers, such as the spacers 310a-f,
are placed between the skin and the lower pressing plate 222. The
spacers are used to adjust the diameter of pressed dough balls that
are processed in the pressing station 106. For example, spacers
between the skin 118 and the upper pressing plate 114 and spacers
between a skin and the lower pressing plate 222 are used at the
same time to adjust thickness uniformity of dough balls pressed
during a press cycle. In another example, there are one or more
spacers between a skin and the lower pressing plate 222 and no
spacers are used between the skin 118 and the upper pressing plate
114.
In some implementations, the dough pressing apparatus 100 does not
include the lower pressing platen 120. For example, the conveyor
102 includes a product support that applies pressure to a bottom
surface of the conveyor 102 and supports the conveyor 102 when the
upper pressing platen 110 is forming the pressed dough balls 108.
In these implementations, the pressed dough balls 108 are formed by
the pressures applied to the balls of dough by the product support
and the upper pressing platen 110 instead of the upper pressing
platen 110 and the lower pressing platen 120.
FIGS. 9A-B illustrate examples of spacers used to adjust dough
thickness. A pressure pump 900a, shown in FIG. 9A, can be used as a
spacer to adjust the amount of pressure applied to specific
locations of the skin 118. For example, a plurality of pressure
pumps 900a can be located in the upper pressing plate 114 where
each of the pressure pumps 900a applies pressure downward onto
different portions of the skin 118.
The pressure pump 900a includes a hollow cylinder 902 that is
filled with a heat conducting fluid 904. When the heat conducting
fluid 904 is pumped into the hollow cylinder 902, the heat
conducting fluid 904 applies pressure on a heat conducting cylinder
906.
The amount of pressure the heat conducting fluid 904 places on the
heat conducting cylinder 906 adjusts the distance d that the heat
conducting cylinder 906 extends from a bottom end of the hollow
cylinder 902 and past the bottom end of the upper pressing plate
114. As the distance d is adjusted, the amount of pressure applied
to the skin 118 changes, adjusting the thickness and diameter of
dough balls pressed at the corresponding location of the skin.
The upper pressing platen 110 includes one pressure pump for each
square half-inch area of the upper pressing plate 114. For example,
the bottom surface of the upper pressing plate 114 includes a
plurality of apertures, where each aperture is about 1/2 by about
1/2 inch square and contains a pressure pump. The pressure pumps
are attached to the aperture with adhesive. In some
implementations, the pressure pumps are attached to the aperture
with screws.
The pressure of each of the pressure pumps 900a is adjustable
separately from the other pressure pumps 900a so that the distance
between the upper surface of the skin 118 and the upper pressing
plate 114 is customizable for each half inch square. The use of the
grid of pressure pumps allows the upper pressing platen 110 to
accommodate multiple different dough ball patterns, for example
4.times.4 and 5.times.5, without removing the skin 118 from the
upper pressing platen 110. In some implementations, the grid of
pressure pumps allows the thickness of pressed dough balls to be
changed dynamically based on the measured diameters of the pressed
dough balls.
In certain implementations, the pressure pump 900a is circular with
a diameter corresponding to the desired diameter of a pressed dough
ball. For example, when the upper pressing platen 110 is configured
for a 3.times.3 pattern of dough balls and a desired diameter of 10
inches, the upper pressing plate 114 has a length and width of 42
inches, includes nine pressure pumps corresponding to the 3.times.3
pressing pattern, and each of the pressure pumps has a 12 inch
diameter.
The hollow cylinder 902 includes one or more heating coils 908a-d
located in the hollow portion of the hollow cylinder 902. The
heating coils 908a-d are used to heat the heat conducting fluid 904
to ensure a uniform processing temperature of the balls of dough
during pressing.
The heat conducting fluid 904 is an oil with good thermal
conductive properties that transfers heat from the heating coils
908a-d to the skin 118. In certain implementations, the heat
conducting fluid 904 is a gas, such as Argon. The heat conducting
fluid 904 has a thermal conductivity of between about 10 to about
250 W/(m*K). In some implementations, the thermal conductivity of
the heat conducting fluid 904 is selected to be between about 30
and about 500 W/(m*K). The heat conducting cylinder 906 is solid
and has a thermal conductivity between about 5 to about 5500
W/(m*K), preferably between about 30 to about 1500 W/(m*K), more
preferably between about 30 to about 500 W/(m*K).
In some implementations, the pressure pump 900a is square with a
length between about 1/4 to about 3 inches. For example, the
pressure pump 900a has a length and a width of about 1 inch and the
upper pressing platen 110 includes a grid of the pressure
pumps.
FIG. 9B shows an example of a pressure bladder 900b (e.g., a
spacer) used to apply pressure to the skin 118 and adjust the
diameter of a pressed dough ball. The pressure bladder 900b
includes a rubber bladder 910 that is filled with the heat
conducting fluid 904.
A bottom end of the rubber bladder 910 is fit into a groove on an
upper surface of a heat transfer plate 912 and a pump connects to
the rubber bladder 910 and adjusts the pressure of the heat
conducting fluid 904 in the rubber bladder 910.
The heat conducting fluid 904 heats the heat transfer plate 912,
which conducts the heat to the skin 118 in order to control the
processing temperature of balls of dough pressed by the upper
pressing platen 110. The heat conducting fluid 904 applies pressure
to the heat transfer plate 912, based on the pressure of the heat
conducting fluid 904 in the rubber bladder 910, adjusting the
distance d between the upper pressing plate 114 and the skin 118.
As the distance d changes the thickness of dough pressed at a
position corresponding to the pressure bladder 900b changes.
The heat transfer plate 912 has a thermal conductivity between
about 5 to about 5500 W/(m*K), preferably between about 30 to about
500 W/(m*K). In some implementations, the rubber bladder 910 is
composed of silicone, has a maximum service temperature of about
550.degree. F., and a flexural strength of 22,800 PSI.
In some implementations, the pressure bladder 900b has an
approximately square shape with a length between about 1/4 to about
3 inches, preferably between about 1/2 to about 11/2 inches, and a
grid of pressure bladders 900b are disposed in the upper pressing
plate 114.
In certain implementations, the pressure bladder 900b is circular
with a diameter associated with a desired diameter of the pressed
dough balls. For example, the pressure bladder 900b has a diameter
of 7 inches and the desired diameter is 8 inches. In these
implementations, the upper pressing platen 110 includes a plurality
of pressure bladders 900b corresponding to a pattern of dough balls
processed by the upper pressing platen 110.
FIG. 10 is an example of a system 1000 for identifying a thickness
adjustment for a spacer in a dough pressing apparatus. The system
1000 includes a monitoring station 1002 that identifies the
diameter of dough pressed in a dough forming apparatus 1004. The
pressed dough is monitored after the dough has been pressed in the
dough forming apparatus 1004 and baked in an oven (not shown).
Alternatively, the monitoring station 1002 is physically located
directly after the dough forming apparatus 1004 and before the
oven.
The monitoring station 1002 averages a plurality of diameters of
each dough ball to account for dough that is not a perfect circle
but is otherwise acceptable and a product rejection station 1006
removes from the system 1000 any pressed dough balls that have an
actual diameter that varies from a desired diameter by more than a
threshold variance.
The monitoring station 1002, the dough forming apparatus 1004, and
the product rejection station 1006 are connected using a network
1008. For example, the network 1008 is a local area network at a
production facility that allows a remote user to monitor the
production facility. In another example, the network 1008 connects
separate stations in a production line and does not allow remote
access to the status of the system 1000.
One or more monitoring cameras 1010 capture images (e.g., a video
stream) of pressed dough balls as the pressed dough balls pass
through the monitoring station 1002. A product analysis module 1012
receives the captured images from the monitoring cameras 1010 and
identifies two or more diameters for each pressed dough ball in the
captured images. For example, the product analysis module 1012
identifies between about 8 and about 124 diameters, preferably
between about 16 and about 96 diameters, for each pressed dough
ball.
In some implementations, the product analysis module 1012 is
configured to identify differences in color between the pressed
dough balls and a conveyor transporting the pressed dough balls.
For example, the product analysis module 1012 receives parameters
indicating the hue, saturation, and value (HSV) of the pressed
dough balls so that the product analysis module can easily locate
pressed dough balls positioned on the conveyor.
The product analysis module 1012 combines the multiple diameters
associated with a specific pressed dough ball to determine an
estimated diameter for the specific pressed dough ball. For
example, the product analysis module 1012 determines the average of
the diameter values.
In another example, the product analysis module 1012 determines a
variance from a desired diameter for each of the multiple diameters
and identifies an estimated diameter for the specific pressed dough
ball based on the variance values. For example, the product
analysis module 1012 applies weights to the variance values based
on the value of the variance and combines the weighted variance
values. In some implementations, larger variance values are
weighted more than smaller variance values.
The product analysis module 1012 retrieves recipe parameters from a
product parameter database 1014 and compares the retrieved recipe
parameters to the estimated dough ball diameter. The recipe
parameters indicate the desired diameter and variance threshold
values for the dough currently being processed by the system 1000.
For example, the recipe parameters can include an over variance
threshold value, used when the measured diameter is greater than a
desired diameter, and an under variance threshold value, used when
the measured diameter is smaller than the desired diameter.
The product analysis module 1012 presents the recipe parameters and
the estimated dough ball diameters on a monitor 1016. For example,
the product analysis module 1012 presents product comparison
information to a user of the system 1000. In some implementations,
the user can adjust the recipe parameters based on the comparison
information.
A spacer adjustment module 1018 receives the estimated dough ball
diameters and the desired diameter from the product analysis module
1012 and retrieves production history information. For example, the
spacer adjustment module 1018 identifies the specific location
where a monitored dough ball was pressed in a pressing pattern.
The spacer adjustment module 1018 determines the diameter variances
for each of the dough balls pressed at that specific location to
determine an average estimated diameter for the dough balls
produced for the current recipe at the specific pressing pattern
location. In some implementations, the spacer adjustment module
1018 presents the average estimated diameter variance for the
specific pressing pattern location on the monitor 1016.
The spacer adjustment module 1018 determines the average diameter
variances for each dough ball location in the pressing station to
create a grid of variance values that corresponds with the pressing
pattern of the current recipe. The spacer adjustment module 1018
compares the grid of variance values with information in a
production history database 1020 to identify history information
similar to the grid of variance values.
Based on the information retrieved from the production history
database 1020, the spacer adjustment module 1018 identifies
thickness adjustments for the spacers in the pressing station so
that the actual diameters of dough pressed in the pressing station
has a smaller variance from the desired diameter for the current
recipe than the current variance.
In some implementations, the production history database 1020 is
created during testing of pressing pattern layouts. Spacer
thickness changes are monitored during the testing of a specific
pressing pattern layout to identify the spacer adjustments that
work best for the pressing pattern layout and a specific grid of
variance values. For example, the spacer adjustment module 1018
records the actual pressed dough diameters measured before and
after a spacer thickness adjustment and the values associated with
the spacer thickness adjustment. The spacer adjustment module 1018
classifies the spacer thickness adjustments to determine which
spacer thickness adjustments reduced the combined variance in a
grid of variance values in order to produce pressed dough ball
diameters with less variance from the desired diameter.
After testing, when the spacer adjustment module 1018 receives
information related to pressed dough balls made according to a
recipe, the spacer adjustment module 1018 identifies a spacer
thickness adjustment with a first grid similar to the current grid
of variance values in order to reduce the variance between the
pressed dough ball diameters and the desired diameter. For example,
the spacer adjustment module 1018 identifies the record or records
in the production history database 1020 that most closely match the
current grid of variance values in order to generate a
recommendation of spacer thickness changes.
A spacer thickness recommendation specifies the total thickness of
a spacer used in a pressing pattern. In other implementations, a
spacer thickness recommendation indicates a recommended change to a
current spacer thickness. For example, a spacer thickness
recommendation can indicate that 0.025 inches should be removed
from a specific spacer.
In some implementations, the spacer adjustment module 1018 updates
the production history database 1020 based on recommendations made
by the spacer adjustment module 1018 and spacer adjustments made
according to the recommendations. For example, if the spacer
adjustment module 1018 presents a user with a grid of spacer
thickness adjustments on the monitor 1016, once production in the
system 1000 continues, the spacer adjustment module 1018 identifies
the new actual diameters of the pressed dough balls and correlates
the new actual diameters with the spacer thickness adjustments and
the actual diameters before the thickness adjustments were
made.
The spacer adjustment module 1018 optionally uses machine learning
to update the production history database 1020 in order to make
accurate spacer adjustment recommendations. For example, machine
learning is used to compensate for potential variances between
different dough processing systems.
In certain implementations, when the dough forming apparatus 1004
can adjust the spacer thicknesses on the fly, the spacer adjustment
module 1018 provides spacer adjustment parameters to a pressing
plate module 1022. For example, the pressing plate module 1022 uses
the spacer adjustment parameters to change the pressure applied to
a specific portion of a skin and the diameter of dough pressed at
that specific portion of the skin, reducing the variance between
the dough diameter and a desired diameter.
When the product analysis module 1012 identifies a pressed dough
ball that does not meet requirement standards, the product analysis
module 1012 optionally provides a message to a product rejection
module 1024. The product rejection module 1024 controls a product
rejection device in the product rejection station 1006 that removes
rejected pieces of dough from the system 1000 when the rejected
pieces do not meet specific standards.
For example, when the product analysis module 1012 identifies a
piece of dough that is burnt, has cracks or holes, does not have
the shape specified by the recipe, or with a size variance that is
greater than a threshold variance, the product rejection module
1024 can remove the piece of dough from the system 1000.
FIG. 11 illustrates an example user interface 1100 for entering
recipe parameters. The user interface 1100 includes a recipe entry
section 1102 and an information section 1104. The recipe entry
section 1102 presents details about the current recipe a dough
pressing apparatus is using.
For example, the recipe entry section 1102 includes a product ID
1106 and a product description 1108. The product ID 1106 is a
unique identifier specific to a single product or product recipe.
When a recipe is initially entered into a dough pressing apparatus,
a user provides the product ID 1106 to the system. The product
description 1108 allows a user to enter a general description of
the recipe used for the product. For example, if two product IDs
are "10 inch" and "10 inch e" the corresponding descriptions can be
"standard" and "elliptical" respectively. In some implementations,
the product description 1108 allows a user to enter more detailed
information about a product or recipe than can be entered in the
product ID 1106.
The recipe entry section 1102 includes a diameter parameter section
1110 that allows a user to enter information about the desired
diameter of pressed dough balls. For example, an elliptic selection
1112 allows a user to specify if the desired dough ball shape is
elliptic (e.g., "On") or circular (e.g., "Off"). In some
implementations, when the desired dough ball shape is elliptic, the
diameter parameter section includes a foci distance field. The foci
distance field receives input from a user specifying the desired
distance between the two foci in elliptically shaped pressed dough
balls.
The diameter parameter section 1110 includes a minimum desired
diameter field 1114, a target desired diameter field 1116, and a
maximum desired diameter field 1118 in the diameter parameter
section 1110. When a monitoring station identifies a pressed dough
ball with an actual diameter outside of the diameter range provided
in the diameter parameter section 1110, a product rejection station
can remove the pressed dough ball from the system that includes the
dough pressing apparatus.
For example, if a pressed dough ball has an average diameter
smaller than the minimum desired diameter, the product rejection
station removes the pressed dough ball from the system. In another
example, when multiple diameters are measured for a pressed dough
ball, if any of the multiple diameters is greater than the maximum
desired diameter, the product rejection stations removes the
pressed dough ball from the system.
When a system uses a maximum variance value is used instead of a
maximum and/or minimum diameter, the maximum variance value can be
based on the maximum and/or minimum diameter. Alternatively, the
diameter parameter section 1110 includes a maximum variance value
field.
In some implementations, the recipe entry section 1102 includes an
average diameter section 1120. The average diameter section 1120
includes a minimum average field 1122 and a maximum average field
1124 that receive an average minimum and maximum respectively from
a user. When using the average diameter section 1120, the minimum
average diameter value and the maximum average diameter value are
compared with the actual average diameter of a measured dough ball
to determine if the measured dough ball should be rejected from the
system or if the thickness of a spacer should be adjusted in a
dough pressing apparatus.
The recipe entry section 1102 includes one or more sections for
entry of additional product rejection parameters. For example, the
user interface 1100 includes an edge flats section 1126 that
receives input indicating an acceptable edge defect value of the
pressed dough balls. The acceptable edge defect value, for example,
specifies the number of contiguous measured diameters for a single
pressed dough ball that can be less than a minimum desired diameter
or more than a maximum desired diameter.
In one example, the maximum number of edge flats is 12, the desired
dough diameter is 10 inches, and the threshold variance is 0.5
inches. If a product analysis module identifies thirteen adjacent
measured diameters of a specific pressed dough ball that are less
than 9.5 inches, then the product analysis module determines that
the specific pressed dough ball does not meet the diameter
requirements. If the product analysis module determines that there
are at most seven adjacent measured diameters of a specific pressed
dough ball that vary from the desire dough diameter by more than
the threshold variance, then the product analysis module determines
that the specific pressed dough ball meets the diameter
requirements.
In certain implementations, the recipe entry section 1102 includes
a dent specification section. For example, the dent specification
section receives input from a user that specifies the maximum size
and shape of allowable dents in pressed dough balls. If a
monitoring station identifies a dent in a pressed dough ball where
the dent is outside of the dent parameters, the rejection station
removes the pressed dough ball from the system. In some
implementations, the dent specification section includes one or
more fields for parameters associated with cracks or other
potential deformations in pressed dough balls.
In one example, the recipe entry section 1102 includes a dough
color section that allows a user to specify acceptable color ranges
of the pressed dough balls. For example, after the pressed dough
balls have been baked, a monitoring station determines if a pressed
dough ball includes discolorations cause by overheating during the
baking process. If the monitoring station identifies a pressed
dough ball with a discoloration, the pressed dough ball can be
moved to another system. In some implementations, the monitoring
station identifies discolorations caused during the pressing
processes.
The recipe entry section 1102 allows a user to delete a recipe,
make changes to a recipe and save the changes, and cancel changes
made to a recipe currently presented in the user interface 1100.
For example, a user can delete a recipe that is no longer in use
after testing multiple similar recipes and selecting a preferred
recipe. In another example, a user can adjust or view recipe
settings for a recipe currently in use by a dough pressing
apparatus. Selection of a save or a cancel button will return the
user interface to a main screen (e.g., shown in FIG. 13).
Alternatively, a user can select a main screen button 1128 to
return to the main screen.
In some implementations, the information section 1104 presents
information about the recipe currently in use by the dough pressing
apparatus. For example, a current monitoring camera view 1130
presents the user with a view of the pressed dough balls moving
through the system.
FIG. 12 illustrates an example user interface 1200 presenting a
grid of average variance values 1202. The grid of average variance
values 1202 represents the average diameter variance from a desired
diameter for each location in a pattern of dough balls. The grid of
average variance values 1202 is used to identify where the
thickness of a spacer in a pressing apparatus should be
adjusted.
For example, a first pressing pattern location 1204 indicates that
the average diameter of a ball of dough pressed at a corresponding
location in the pressing apparatus is +0.4 inches greater than the
desired diameter of 10 inches. The first pressing pattern location
1204 can present information indicating the range of diameters for
balls of dough pressed at the corresponding location. For example,
the minimum diameter of a dough ball corresponding with the first
pressing pattern location 1224 is 10.3 inches and the maximum
diameter is 10.6 inches.
Based on the variance values in the grid of average variance values
1202, a spacer adjustment pattern can be determined. For example, a
thickness adjustment for a spacer corresponding to the first
pressing pattern location 1204 can be based on the variance
specified by the first pressing pattern location 1204 and the
adjacent pressing pattern locations. In this example, a variance of
-0.3 inches at a second pressing pattern location 1206, a variance
of +0.4 inches at a third pressing pattern location 1208, and a
variance of +0.2 inches at a fourth pressing pattern location 1210
are used to determine the spacer thickness adjustment corresponding
to the first pressing pattern location 1204. In another example,
the variances at the first pressing pattern location 1204, the
second pressing pattern location 1206, and the third pressing
pattern location 1208 are used to determine a thickness adjustment
for the spacer associated with the first pressing pattern location
1204.
In some implementations, the user interface 1200 includes a pressed
dough preview section 1212. For example, one or more video cameras
in a monitoring station capture a video sequence of pressed dough
passing on a conveyor through the monitoring station and the video
sequence is presented in the pressed dough preview section
1212.
A user can view the pressed dough preview section 1212 to see the
dough as it passes through the monitoring station and determine if
recipe parameters should be adjusted. For example, the user can
change recipe parameters in the user interface 1100 by selecting a
recipe button 1214.
The pressed dough preview section 1212 includes markers that
indicate the quality of the pressed dough passing through the
monitoring station. For example, a first marker 1216 indicates that
a pressed dough ball has little variance from the desire recipe
parameters, a second marker 1218 indicates that an associated piece
of dough has some variances from the desired recipe parameters, and
a third marker 1220 indicates that a corresponding dough piece has
a greater variance and should be discarded.
In some implementations, the markers are colored squares that
surround pieces of dough as the dough pieces are presented in the
pressed dough preview section 1212. In other implementations,
pieces of dough are highlighted with a color based on the quality
of the dough circling the piece of dough.
The pressed dough preview section 1212 allows the user to identify
defective dough before a product rejection system removes the
defective dough from the processing system.
In certain implementations, the grid of average variance values
1202 includes spacer adjustment recommendations 1222a-d. For
example, a spacer adjustment module identifies shim thickness
adjustments to make based on the grid of average variance values
1202 and presents the spacer adjustment recommendations 1222a-d
with the grid of average variance values 1202 on a monitor.
A user of a dough pressing apparatus can view the spacer adjustment
recommendations 1222a-d in order to determine adjustments to make,
during a maintenance cycle, to spacers placed on a skin.
Presentation of the spacer adjustment recommendations 1222a-d
allows the user to more easily identify where space adjustments are
needed and how much of an adjustment to make.
FIG. 13 illustrates an example user interface 1300 presenting
recipe history information. The history information includes data
about the recipe currently running and the dough parameters
measured during the current run time. For example, the user
interface 1300 includes a recipe information section 1302 and a
statistical distribution graph 1304 of the measure diameters of the
pressed dough balls. The recipe information section 1302 includes
the name of the recipe currently running on a dough pressing
apparatus and the total number of times the recipe has run.
The statistical distribution graph 1304 presents the average
measured dough ball diameter for the current recipe process and the
standard deviation from the average. The statistical distribution
graph 1304 presents the actual measured dough ball diameters with
respect to the average diameter. In some implementations, the
statistical distribution graph 1304 presents information associated
with acceptable pressed dough balls, and information associated
with discarded pressed dough balls is not included.
The user interface 1300 includes a start time section 1306 and an
elapsed time section 1308. The start time section 1306 presents the
time that the current recipe process was started. In some
implementations, the start time section 1306 includes both the time
and the date that the process was started. The elapsed time section
1308 indicates the total time that the current recipe process has
been running.
A recipe overview section 1310 presents general information about
the current run of the recipe. For example, the recipe overview
section 1310 includes the total number of pressed dough balls that
have been processed during the current recipe process, the total
number of pressed dough balls that meet the recipe parameters, and
the total number of pressed dough balls that have been rejected by
a monitoring system. In certain implementations, the recipe
overview section 1310 includes percentages associated with accepted
pressed dough balls and rejected pressed dough balls.
In some implementations, the user interface 1300 includes
additional information about the current recipe process. For
example, a production run section 1312 presents a breakdown of
statistics for the current recipe process. Information presented in
the production run section 1312, for example, can be based on the
recipe parameters included in the recipe entry section 1102.
The production run section 1312 includes statistics on the maximum
and minimum diameters measured for each pressed dough ball and the
average diameter for each pressed dough ball. For example, when a
specific pressed dough ball is measured by a monitoring station,
the monitoring station can measure about 64 diameters of the
specific pressed dough ball. A product analysis module determines
the major and minor diameters from the 64 measured diameters and
updates the "DIA MAJOR" and "DIA MINOR" statistics respectively.
The product analysis module averages all of the 64 measured
diameters and updates the "DIA AVG" statistic. If the major and
minor diameters are within an acceptable range (e.g., determined
based on the minimum desired diameter field 1114 and the maximum
desired diameter field 1118) and the average diameter is acceptable
(e.g., based on the minimum average field 1122 and the maximum
average field 1124) the specific pressed dough ball is kept. If one
of the values is outside of an acceptable range, a product
rejection station can remove the specific pressed dough ball from
the dough pressing system.
FIG. 14 illustrates another example user interface 1400 presenting
recipe history information. The user interface 1400 includes a
recipe detail section 1402 that presents recipe specific
information. For example, the recipe detail section 1402 includes
the product ID, the target size (e.g., desired diameter), and the
diameter variance acceptable for the product. The recipe detail
section 1402 presents information to a user without allowing the
user to change the information.
The recipe detail section 1402 includes average values for the
measure diameters of the pressed dough balls. Additionally, the
recipe detail section 1402 includes the average major and minor
pressed dough ball diameters. The average major and minor pressed
dough ball diameters can be used to determine the range of sizes of
the pressed dough balls.
In some implementations, the major and minor pressed dough ball
diameters are used to determine the shape of the pressed dough
balls. For example, when the difference between the average major
and minor pressed dough ball diameters is small, the pressed dough
balls are more circular in shape, and when the difference between
the average major and minor diameters is larger, the pressed dough
balls have more of an elliptical shape.
A product size run selection 1404 allows a user to select the
recipe history information to present in the user interface 1400.
For example, a user is presented with a list of recipes previously
run on a dough pressing apparatus and the user selects one of the
recipes to view information about the previously run recipe.
Changing the product size run selection 1404 changes the process
parameters presented in the recipe detail section 1402.
The user interface 1400 includes a grid of pressed dough ball
variances 1406 and measured diameters associated with the
variances. For example, when a pattern of dough balls is a
4.times.4 grid, the grid of pressed dough ball variances 1406
includes sixteen variance values and the maximum and minimum
average diameters measured at the pressing pattern locations
associated with the corresponding variances.
FIGS. 15A-B show an example of a product monitoring station 1500.
The product monitoring station 1500 includes a housing 1502 for one
or more monitoring cameras (not shown) that capture a video stream
of pressed dough balls transported on a conveyor 1504.
The video stream captured by the monitoring cameras is used to
identify defective pressed dough balls so that a product rejection
station 1506 can remove the defective pressed dough balls from the
conveyor 1504. The product monitoring station 1500 includes a
secondary conveyor 1508 that transports the defective pressed dough
balls once the defective pressed dough balls have been removed from
the conveyor 1504.
FIG. 15B is an example of the product rejection station 1506
included in the product monitoring station 1500. The product
rejection station 1506 includes a plurality of rejection devices
1510 that remove the defective pressed dough from the conveyor
1504.
A product analysis module analyzes the video stream captured by the
monitoring cameras and identifies defective pressed dough balls in
the video stream. The product analysis module determines the
location of a defective pressed dough ball on the conveyor 1504 and
the time that the defective pressed dough ball will pass underneath
a specific one of the rejection devices 1510. When the defective
pressed dough ball passes underneath the specific rejection device
1510, the rejection device 1510 moves the defective pressed dough
ball to the secondary conveyor 1508 while acceptable pressed dough
balls move automatically to another conveyor (not shown) adjacent
to the conveyor 1504.
In some implementations, automatic removal of pressed dough balls
that do not meet recipe requirements increases throughput of a
dough pressing apparatus.
In certain implementations, the rejection devices 1510 remove
defective pressed dough balls from the system mechanically. In
other implementations, the rejection devices 1510 remove defective
pressed dough balls from the system with a blast of air. For
example, when the defective pressed dough ball is moving from the
conveyor 1504 to an adjacent conveyor, a blast of air from one of
the rejection devices 1510 blows downward on the defective pressed
dough ball when the defective pressed dough ball is moving from the
conveyor 1504 to the adjacent conveyor, and the defective pressed
dough ball lands on the secondary conveyor 1508.
FIG. 16 is a schematic diagram of a generic computer system 1600.
The system 1600 is optionally used for the operations described in
association with any of the computer-implemented methods described
previously, according to one implementation. The system 1600
includes a processor 1610, a memory 1620, a storage device 1630,
and an input/output device 1640. Each of the components 1610, 1620,
1630, and 1640 are interconnected using a system bus 1650. The
processor 1610 is capable of processing instructions for execution
within the system 1600. In one implementation, the processor 1610
is a single-threaded processor. In another implementation, the
processor 1610 is a multi-threaded processor. The processor 1610 is
capable of processing instructions stored in the memory 1620 or on
the storage device 1630 to display graphical information for a user
interface on the input/output device 1640.
The memory 1620 stores information within the system 1600. In one
implementation, the memory 1620 is a computer-readable medium. In
one implementation, the memory 1620 is a volatile memory unit. In
another implementation, the memory 1620 is a non-volatile memory
unit.
The storage device 1630 is capable of providing mass storage for
the system 1600. In one implementation, the storage device 1630 is
a computer-readable medium. In various different implementations,
the storage device 1630 is optionally a floppy disk device, a hard
disk device, an optical disk device, or a tape device.
The input/output device 1640 provides input/output operations for
the system 1600. In one implementation, the input/output device
1640 includes a keyboard and/or pointing device. In another
implementation, the input/output device 1640 includes a display
unit for displaying graphical user interfaces.
In some examples, the features described are implemented in digital
electronic circuitry, or in computer hardware, firmware, software,
or in combinations of them. The apparatus is optionally implemented
in a computer program product tangibly embodied in an information
carrier, e.g., in a machine-readable storage device or in a
propagated signal, for execution by a programmable processor; and
method steps are performed by a programmable processor executing a
program of instructions to perform functions of the described
implementations by operating on input data and generating output.
The described features are optionally implemented advantageously in
one or more computer programs that are executable on a programmable
system including at least one programmable processor coupled to
receive data and instructions from, and to transmit data and
instructions to, a data storage system, at least one input device,
and at least one output device. A computer program is a set of
instructions that are optionally used, directly or indirectly, in a
computer to perform a certain activity or bring about a certain
result. A computer program is optionally written in any form of
programming language, including compiled or interpreted languages,
and it is deployed in any form, including as a stand-alone program
or as a module, component, subroutine, or other unit suitable for
use in a computing environment.
Suitable processors for the execution of a program of instructions
include, by way of example, both general and special purpose
microprocessors, and the sole processor or one of multiple
processors of any kind of computer. Generally, a processor will
receive instructions and data from a read-only memory or a random
access memory or both. The essential elements of a computer are a
processor for executing instructions and one or more memories for
storing instructions and data. Generally, a computer will also
include, or be operatively coupled to communicate with, one or more
mass storage devices for storing data files; such devices include
magnetic disks, such as internal hard disks and removable disks;
magneto-optical disks; and optical disks. Storage devices suitable
for tangibly embodying computer program instructions and data
include all forms of non-volatile memory, including by way of
example semiconductor memory devices, such as EPROM, EEPROM, and
flash memory devices; magnetic disks such as internal hard disks
and removable disks; magneto-optical disks; and CD-ROM and DVD-ROM
disks. The processor and the memory are optionally supplemented by,
or incorporated in, ASICs (application-specific integrated
circuits).
To provide for interaction with a user, the features in some
instances are implemented on a computer having a display device
such as a CRT (cathode ray tube) or LCD (liquid crystal display)
monitor for displaying information to the user and a keyboard and a
pointing device such as a mouse or a trackball by which the user
provides input to the computer.
The features are optionally implemented in a computer system that
includes a back-end component, such as a data server, or that
includes a middleware component, such as an application server or
an Internet server, or that includes a front-end component, such as
a client computer having a graphical user interface or an Internet
browser, or any combination of them. The components of the system
are connected by any form or medium of digital data communication
such as a communication network. Examples of communication networks
include, e.g., a LAN, a WAN, and the computers and networks forming
the Internet.
The computer system optionally includes clients and servers. A
client and server are generally remote from each other and
typically interact through a network, such as the described one.
The relationship of client and server arises by virtue of computer
programs running on the respective computers and having a
client-server relationship to each other.
A number of embodiments have been described. Nevertheless, it will
be understood that various modifications are optionally made
without departing from the spirit and scope of this disclosure.
Accordingly, other embodiments are within the scope of the
following claims.
* * * * *
References